Manitou Dorado Service guide

1

DORADO SERVICE GUIDE

Hayes Performance Systems

5800 W. Donges Bay Rd.

Mequon, WI 53092

Tel: 888.686.3472

Email: [email protected]om

Web: www.hayescomponents.com

Hayes Components Europe

Dirnismaning 20 a

85748 Garching (b. Munich)

Germany

ph: +49 (0)89 203237450

Email: [email protected]om

Web: www.hayescomponents.com

2

DORADO SERVICE GUIDE

INTRODUCTION

Suspension forks by design can contain preloaded springs, gases and uids under

extreme pressures. Warnings contained in this manual must be observed to avoid damage to fork,

serious injury or even death.

We highly recommend that service to this fork be performed by a certied bicy-

cle mechanic. Failure to follow instructions presented in this manual could lead to serious injury

or death. Any questions about the servicing of this fork or the manual itself should be directed to

Manitou Customer Support at:

Phone: 888-686-3472

Email: [email protected]om

This manual is intended to guide the user through basic service of Manitou Dorado Pro and Expert front

forks. We highly suggest the service on these forks be performed by an experienced suspension mechanic.

Service is supported by the identication of common parts and assemblies that have been assembled into

Service Kits. The purpose of this manual will be to describe conditions that may drive the need for service

and to provide installation instructions for the kits.

Due to the time-consuming nature of suspension fork service, at this time our primary focus is to oer ser-

vice kits that minimize the amount of downtime and labor involved. Please read through the manual care-

fully before beginning the service of your fork. The Dorado fork service is considerably more involved than a

standard fork service and having a basic understanding of the tasks you are about to perform will assist you

greatly in the disassembly and re-assembly of your fork.

Please read through the required tools page and be sure you have all of the items you will need for the ser-

vice of your fork. The guide is designed to be used with the Dorado Service kit which includes all O-rings and

seals to overhaul the fork. The part number for the kit is 141-25995.

For any assistance with the service of your Dorado please contact our Technical Service Department at 888-

686-3472 and email them at [email protected]

3

DORADO SERVICE GUIDE

Table of contents

SECTION PAGE NUMBER

Damping Leg Service – Disassembly 5–10

Damping Leg Service - Assembly 11–13

Air Leg Service - Disassembly 14–15

Compression Rod Service 16–20

Air Leg Service - Assembly 21–22

Dust and Oil Seal Replacement 23–24

Exploded Diagram & Parts List 25–26

O-Ring Placement Diagrams 27–30

4

DORADO SERVICE GUIDE

REQUIRED TOOLS

Below is a list of tools that will be used in the complete service of a Dorado Pro/Expert fork.

Dorado Clamp Blocks – Manitou Part Number 172-25077

Dorado Seal Press – Manitou Part Number 172-29862

Dorado Service Kit – Includes all O-rings and seals for service. Part number 141-25995

5wt Maxima Fork oil - Manitou part number 85-0023

Slickoleum™ Grease

Torque Wrench

36mm Wrench or Socket (an adjustable wrench can be used instead but care must be taken to not damage

the top caps.)

12mm Combination Wrench

13mm Combination Wrench

20mm Combination Wrench

20mm Crow’s Foot

2mm Allen Wrench

2.5mm Allen Wrench

5mm Allen Wrench

6mm Allen Wrench

26mm Socket with ratchet

Small Flat Blade Screwdriver

Needle Nose Pliers

Pick or similar tool for removing O-rings

Blue Loctite

Safety Glasses

Isopropyl Alcohol

5

DORADO SERVICE GUIDE

1. First step is to loosen the damping leg top cap us-

ing a 36mm wrench. It helps if the leg is still clamped

in the lower crown assembly while breaking the top

cap loose (be sure the upper crown is loosened, you

only want the lower tightened when breaking loose

the top cap). Only loosen the top cap at this point.

Do not remove it. (FIG. 1)

2. Loosen the pinch bolts on the lower crown and

remove the damping leg from the fork. You will need

to remove the frame bumpers to do so. Put them in a

safe place so you do not misplace them.

3. Clamp the upper sleeve of the fork in bike stand.

4. Remove the top cap from the fork leg using a

36mm wrench. The top cap is still attached to the

rebound shaft at this point.

5. You will now remove the top cap from the rebound

shaft. Place a 12mm wrench on the ats of the re-

bound shaft and use a 36mm wrench to unthread

the top cap from the shaft. (FIG. 2) Once the top cap

is unthreaded, remove the rebound knob from the

top cap.

6. Remove the fork leg from the bike stand and pour

the oil out of the leg. (FIG. 3) Slide the inner leg out

of the outer leg and leave the outer leg to drain in a

drainage pan.

7. Holding the inner leg over a drainage pan, stroke

the rebound shaft several times to drain the rest of

the oil from the inner leg.

FIG. 3

FIG. 1

FIG. 2

DAMPING LEG Disassembly

6

DORADO SERVICE GUIDE

8. Wrap the inner leg in a rag and lightly clamp it

into a bike stand with the rebound shaft pointing

down towards the oor.

9. Using a 2mm Allen wrench, remove the TPC+ ad-

juster knob. Remove O-ring and be sure you capture

the 2 detent balls and springs under the knob.

(FIG. 4, 5 & 6)

10. Next you will remove the High Speed adjuster

knob. Remove the c-clip that holds the knob on

using a small at blade screwdriver or similar tool.

(FIG. 7) Once the c-clip is removed pull the knob

up. Be sure to capture the O-ring, 2 detent balls and

springs under the knob. (FIG. 8)

FIG. 6

FIG. 4

FIG. 5

FIG. 7

FIG. 8

DAMPING LEG Disassembly

7

DORADO SERVICE GUIDE

11. Remove the damping cartridge from the inner

leg using a 26mm socket. Pull the damping cartridge

completely out of the inner leg. (FIG. 9 &10)

12. You will notice the damping cartridge has two

larger diameter sections at the ends. These are called

the Outer Cartridge Adapters. Using the Dorado

Clamp Blocks (Part # 172-25077), clamp the outer

cartridge adapter on the rebound end in a vise.

13. Using a 20mm wrench, remove the rebound

damper from the cartridge. (The inner cartridge

tube will come out with either the rebound assem-

bly or compression assembly. If it comes out with

the rebound, pull the tube o of the assembly.)

(FIG. 11 & 12)

FIG. 9

FIG. 10

FIG. 11

FIG. 12

DAMPING LEG Disassembly

8

DORADO SERVICE GUIDE

14. Replace the following O-rings on the rebound

damper assembly. You can also refer to the Rebound

Assembly Diagram on Page 23 to see the placement

of the O-rings on the assembly.

A. O-ring #064962 - This is the O-ring above the

threads on the end of the damper assembly.

(FIG. 13)

B. O-ring #100-121 - This is the larger O-ring on the

bottom out end cap. (FIG. 14)

C. O-ring #100-014 - This is the smaller O-ring on the

bottom out end cap. (FIG. 15)

FIG. 13

FIG. 14

FIG. 15

DAMPING LEG Disassembly

9

DORADO SERVICE GUIDE

15. Clamp the outer cartridge adapter on the compression damper side

using the Dorado Clamp Blocks. (FIG. 16)

16. Remove the TPC+ Compression assembly from the cartridge using

a 26mm socket. (The inner cartridge tube will come out with either the

rebound assembly or the compression assembly. Pull the tube o of the

assembly.) (FIG. 17 & 18)

17. Remove the top cap and nylon washer from the assembly. This is re-

quired to replace the O-rings included in the service kit for the compression

assembly. (FIG. 19)

FIG. 16

FIG. 17

FIG. 18

FIG. 19

DAMPING LEG Disassembly

10

DORADO SERVICE GUIDE

18. Replace the following O-rings on the compression assembly top cap.

A. O-ring # 08-29433-L026 - This is the O-ring that is around the outside of

the compression assembly top cap. (FIG. 20)

B. O-ring # 100-023 - This O-ring is located in an inside groove in the top cap.

It is directly behind the two pins. (FIG. 21)

C. O-ring # 101-1250-200 - This O-ring is located just below the top opening

on the top cap where the adjuster slides through. (FIG. 22)

19. Press the top cap back onto the compression assembly. (FIG. 23)

FIG. 20

FIG. 21

FIG. 22 FIG. 23

DAMPING LEG Disassembly

11

DORADO SERVICE GUIDE

1. Inspect the inner and outer damper tubes and be

sure they are free from debris and contaminants.

2. Press the inner damper tube onto the rebound

assembly.

3. Clean the threads on the outer cartridge adapter

with isopropyl alcohol and apply Blue Loctite to the

threads. Install the rebound damper assembly into

the outer cartridge. Only tighten to hand tight at this

point.

4. Clean the threads on the second outer cartridge

adapter and apply blue Loctite to them. Install the

TPC+ compression assembly into the cartridge.

5. Using a 26mm socket and 20mm wrench, tighten

both the compression assembly and rebound as-

sembly to 6.8 N m (60 in lb). (FIG. 1 &2)

6. Put a small amount of Slickoleum Grease on the

O-ring on the rebound end of the damper cartridge

assembly. Install the assembly in the inner leg by

sliding it into the bottom of the leg. Use a 26mm

socket to tighten it into the leg. Tighten to 6.8 N m

(60 in lb). (FIG. 3)

FIG. 1

FIG. 3

FIG. 2

DAMPING LEG assembly

12

DORADO SERVICE GUIDE

7. Insert the detent springs into opposite holes in

the end cap and place the detent balls on top of

the springs. To hold the detent balls in place on the

spring use a small dab of grease. (FIG. 4)

8. Install the high speed adjuster onto the end cap.

Be sure that O-ring # 100-025 below the adjuster

is in place and greased. (FIG. 5) Secure the adjuster

with the c-clip.

9. Insert the springs into opposite holes on the

TPC+ adjuster knob and then place the detent balls

in the corresponding holes of the high speed adjust-

er knob. (FIG. 6) Place O-ring # 100-024 around the

TPC+ knob and apply a small amount of grease to it.

(FIG. 7)

10. Install the TPC+ adjuster knob onto the end cap

and secure with the 2mm screw. (FIG. 8)

FIG. 6

FIG. 4

FIG. 5

FIG. 7

FIG. 8

DAMPING LEG SERVICE assembly

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DORADO SERVICE GUIDE

15. Fully extend the rebound shaft, pulling the

inner leg up into the outer leg.

16. Pour damper oil (5wt fork oil) into the leg.

Stroke the rebound shaft to bleed the system and

release the air. You want to stroke the rebound

shaft a few times with the rebound fully closed,

then turn the rebound knob open two clicks coun-

terclockwise. Stroke the rebound shaft another 15-

20 times and the system will be bled. (FIG. 10)

17. Once the system is bled you need to set the

oil height in the leg. The oil height is 110mm. You

measure this by measuring down from the top of

the outer leg to the top of the oil. You want the

inner leg fully compressed into the outer leg when

measuring. (FIG. 11)

18. After you have properly set the oil height fully

extend the inner leg and tighten down the top

cap using a 36mm wrench to the proper torque of

6.8-9.0 N m (60-80 in lb).

19. Reinstall the damping leg into the fork crowns

on the bike.

11. Replace the oil and dust seals on the outer leg

following the directions on pages 22-23. Inspect

the inside of the outer leg and the outside of the

inner leg and be sure they are free from debris and

contaminants. Lube the oil seal and dust wiper on

the outer leg with a small amount of Slickoleum

grease. Slide the inner leg into the outer leg and

clamp into the bike stand.

12. Replace O-ring # 100-027 on the top cap

(FIG. 9)

13. Install the top cap onto the end of the rebound

shaft. Use a 36mm wrench and a 12mm wrench to

tighten to the proper torque of 6.8-9.0 N m

(60-80 in lb).

14. Install the rebound knob into the top cap by

snapping it into place. Fully close the rebound by

turning the knob clockwise.

FIG. 10

FIG. 11

FIG. 9

DAMPING LEG SERVICE assembly

14

DORADO SERVICE GUIDE

1. First, the air pressure needs to be released from

the system. Remove the air cap from the top of the

fork leg, and release the air pressure using a shock

pump. (FIG. 1)

2. The air spring leg top cap needs to be loosened.

Loosen the pinch bolt on the top crown, and crack

the top cap loose with a 36mm wrench.

(FIG. 2)

3. Loosen the pinch bolts on the lower crown, and

remove the leg from the fork. Be sure not to mis-

place the frame bumper that will need to come o

the fork leg. (FIG. 3)

4. Lightly clamp the fork leg in a bike stand. Re-

move the top cap from the leg with a 36mm wrench.

Remove the top cap from the compression rod with

a 13mm wrench on the top of the compression rod

and a 36mm wrench. (FIG. 4)

FIG. 1

FIG. 2

FIG. 3

FIG. 4

air spring LEG disassembly

15

DORADO SERVICE GUIDE

5. Pour the uid out of the leg, and slide the inner

leg out of the outer leg. Remove the outer leg from

the stand and let it sit above a drainage pan. (FIG. 5)

6. Wrap the inner in a rag and clamp it lightly in

the bike stand with the compression rod pointing

towards the ceiling.

7. Loosen the Compression Rod Assembly from the

inner leg with a 20mm wrench. (FIG. 6)

8. Remove Compression Rod Assembly from the in-

ner leg. Note: there may be a small amount of Semi-

bath oil on top of the piston. Remove Semi-bath, this

will be replaced with Slickoleum™ grease (FIG. 7)

FIG. 5

FIG. 6

FIG. 7

air spring LEG disassembly

16

DORADO SERVICE GUIDE

This section covers the complete tear down and

rebuild of the air spring compression rod in the air

leg of the fork.

1. Using the Dorado Clamp Blocks (Part # 172-

25077), clamp the compression rod in a vise. Be sure

to clamp the compression rod near the end or below

the air piston. Do not clamp in the middle of the

shaft. (FIG. 1) Do not clamp the rod in a vise with-

out the clamp blocks. Doing so will damage the rod

rendering it unusable.

2. Next you need to unthread the poppet from the

valve shaft. Insert a 2.5mm Allen wrench into the

center hole of the air piston. (FIG. 2 & 3) You may

have to turn and push lightly on the wrench until

you feel it engage the Allen head inside the shaft.

Turn the wrench counter-clockwise. You will notice

as you are turning the wrench the valve shaft is

moving out of the valve housing on the other end

of the compression rod. (FIG. 4) Keep turning the

wrench until the valve shaft stops moving out of the

housing.

FIG. 1

FIG. 4

FIG. 2

FIG. 3

compression rod service

17

DORADO SERVICE GUIDE

3. Using a 13mm wrench unthread the valve as-

sembly o of the compression shaft and remove the

air valve shaft from the compression rod shaft.

(FIG. 5 & 6)

4. Slide the travel spacer, bottom-out bumper and

end cap o of the compression shaft. (FIG. 7)

5. Using a 6mm Allen wrench unthread the air pis-

ton o of the compression shaft. (FIG. 8) Be careful

when removing the piston as there is a small spring

in the shaft under the piston. (FIG. 9)

FIG. 5

FIG. 6

FIG. 7

FIG. 8

FIG. 9

air spring LEG disassembly

18

DORADO SERVICE GUIDE

6. Insert the valve shaft back into the compression

rod shaft and use it to push the poppet out of the

other end of the compression rod shaft.

(FIG. 10 & 11)

7. Replace O-rings #101-350-150 on the poppet.

(FIG. 12)

8. Replace O-ring #100-214 on the air piston.

(FIG. 13A) Forks produced in 2017 and after will

have the updated piston. (FIG. 13B) Replace Quad

Seal #110-214 on the air piston.

FIG. 10

FIG. 11

FIG. 12

FIG. 13A

FIG. 13B

air spring LEG disassembly

19

DORADO SERVICE GUIDE

9. Replace O-rings 100-026 and 100-110 on the

end cap. (See Page 26, FIG A) Install the end

cap, bottom-out bumper and the travel spacer

back onto the compression rod shaft.

(FIG. 14 & 15)

10. Apply a small amount (too much Loctite will

clog the air shaft assembly) of red Loctite to the

threads of the valve assembly. (FIG. 16) Lightly

grease valve shaft and insert both the valve

shaft and valve assembly into compression rod.

Tighten to 5.1 - 6.2 N m (45 -55 in lb)

(FIG. 17 & 18)

FIG. 14

FIG. 15

FIG. 16

FIG. 17

FIG. 18

air spring LEG disassembly

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Manitou Dorado Service guide

Manitou Dorado Service guide

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